Field joint protection system rain qualification test report

This report documents the procedures, performance, and results obtained from the Field Joint Protection System (FJPS) rain test. This test was performed to validate that the flight configuration FJPS prevents the accumulation of moisture in the redesigned solid rocket motor (RSRM) field joints when subjected to simulated prelaunch natural rain environments. The FJPS test article was exposed to rain simulation for approximately 50 minutes. During the test, water entered through the open upper end of the systems tunnel and was funneled down between the tunnel and case. A sealant void at the moisture seal butt splice allowed this water to flow underneath the FJPS. The most likely cause of voids was improper bondline preparation, particularly on the moisture seal surface. In total, water penetrated underneath approximately 60 percent of the FJPS circumference. Because the test article was substantially different from flight configuration (no systems tunnel closeout), results of this test will not affect current flight motors. Due to the omission of systems tunnel covers and systems tunnel floor plate closeout, the test assembly was not representative of flight hardware and resulted in a gross overtest. It is therefore recommended that the test be declared void. It is also recommended that the test be repeated with a complete closeout of the systems tunnel, sealed systems tunnel ends, and improved adhesive bondline preparation.